Custom Rear Diffuser is in the works!!

[MoPower]

Hi guys, I'm over here now at LXowners.com to spread some Danko Joy:flowers2: So here is a quick synopsis of the fabrication of our next custom piece to be released, the Danko Rear Diffuser!! :dancingpoop:

Here is what it will look like when It's done:

http://i227.photobucket.com/albums/dd110/dankoreproductions/Rear%20Diffuser/WithTooth.jpg


First, I decided where it's edges will be (blue line):

http://i227.photobucket.com/albums/dd110/dankoreproductions/Rear%20Diffuser/diffuser0012.jpg

Next, I fiberglassed up the whole area. this will form the rear flange so I can stick it back on with tape later.

http://i227.photobucket.com/albums/dd110/dankoreproductions/Rear%20Diffuser/diffuser10.jpg

Made a box next and poured a bunch of foam into it:

http://i227.photobucket.com/albums/dd110/dankoreproductions/Rear%20Diffuser/Diffuser_foam.jpg

Next, I sculpted it down more and more, this took a couple of days of serious contemplation and measuring.

http://i227.photobucket.com/albums/dd110/dankoreproductions/Rear%20Diffuser/diffuser_foam1.jpg
http://i227.photobucket.com/albums/dd110/dankoreproductions/Rear%20Diffuser/diffuser_3.jpg
http://i227.photobucket.com/albums/dd110/dankoreproductions/Rear%20Diffuser/asdf0012.jpg
http://i227.photobucket.com/albums/dd110/dankoreproductions/Rear%20Diffuser/asdf0032.jpg
http://i227.photobucket.com/albums/dd110/dankoreproductions/Rear%20Diffuser/werew0012.jpg

Next, the idea is to make it the thickness it's supposed to be all over, around 3/8" . I did this by adding several layers of fiberglass and 2 layers of an 1/8" thick core material. It's finally ready to be removed from the car and trimmed down to the edge of the blue line, so more pics are to come!!

http://i227.photobucket.com/albums/dd110/dankoreproductions/Rear%20Diffuser/dfg0012.jpg
http://i227.photobucket.com/albums/dd110/dankoreproductions/Rear%20Diffuser/df004.jpg

[BOS/SRT]

Mo, wow!!!!! that looks like a lot work, that I wouldn't want to do. :). Thanks for sharing the phases that it takes to create a beautiful Danko Product. Eager to see the final result. Btw, I won't ask anymore. Lol!!!

[MoPower]

Mo, wow!!!!! that looks like a lot work, that I wouldn't want to do. :). Thanks for sharing the phases that it takes to create a beautiful Danko Product. Eager to see the final result. Btw, I won't ask anymore. Lol!!!

You're welcome, and thanks for the invitation to hang out with ya'll!

[MORGAN82]

thats gonne be sick

[DaBlackPearl]

Welcome Mo....I have your products on the front of my ride...may as well get some on the rear.

[MoPower]

Today I got the entire thing grinded to my satisfaction. The next step tomorrow is to start bondoing it up to make it smooth. I will also be extending the lower lip a little further out.

http://i227.photobucket.com/albums/dd110/dankoreproductions/Rear%20Diffuser/wwwww0042.jpg
http://i227.photobucket.com/albums/dd110/dankoreproductions/Rear%20Diffuser/wwwww0032.jpg
http://i227.photobucket.com/albums/dd110/dankoreproductions/Rear%20Diffuser/wwwww0012.jpg

[BOS/SRT]

Mo, as usual, looks like a work of art. I see what you mean about extending the lower lip, but you don't think it looks more streamed lined as is? Looks sick! Now will this fit on a 300 or Magnum as well?
Thanks again!

[MoPower]

Mo, as usual, looks like a work of art. I see what you mean about extending the lower lip, but you don't think it looks more streamed lined as is? Looks sick! Now will this fit on a 300 or Magnum as well?
Thanks again!


If I want to use honeycomb, it has to be extended like in the original render. The only reason it needs extended is because the lower edge never got the 3/8" worth of thickening material so it is not correct yet, I'll do it with bondo instead.

[MoPower]

Extending the bottom edge really did the trick, it is now really looking just like the Rendering I think. I hung the tape in the general area where the bumperettes are gonna be just to try to visualize it. This is really not gonna take that long to finish up, so I think I'll start getting a list of folks who would be interested in getting one for $225. MZGUDZ already has dibs on the first one of course! This is not an official list, just an interest gauge of truly serious parties.

1) MZGUDZ a.k.a. Gudzy
2) ??

http://i227.photobucket.com/albums/dd110/dankoreproductions/Rear%20Diffuser/Chargerdiffuser.jpg
http://i227.photobucket.com/albums/dd110/dankoreproductions/Rear%20Diffuser/ChargerDiffuser1.jpg

[torredguy]

looks real good mo. i like it alot.. cant wait to see it all done..

[MoPower]

Here is the current list:

1) MZGUDZ a.k.a. Gudzy
2) Dchavez
3) jay2puff
4) ecNick
5) CDNChargerRT
6) 6Shooter
7) Rock


How about rubber bumperettes? that would be easy to do.


with bumperettes

http://i227.photobucket.com/albums/dd110/dankoreproductions/Rear%20Diffuser/Chargercustomdiffuserwbumperettescopy.jpg

Without bumperettes

http://i227.photobucket.com/albums/dd110/dankoreproductions/Rear%20Diffuser/Chargercustomdiffusercopy.jpg

[MoPower]

More progress pics - Now that the exact lines are established, the next step is to take seriously accurate measurments and patterns and correct any symmetry problems that may exist.

http://i227.photobucket.com/albums/dd110/dankoreproductions/Rear%20Diffuser/diffuser99.jpg

1) MZGUDZ
2) Dchavez
3) jay2puff
4) ecNick
5) CDNChargerRT
6) 6Shooter
7) ChargerH2O
8) Rock
9) blackhemi

[Shaggy]

Nice work. Does look like a ton of work. The finished product looks damn good!

[MoPower]

NEW DEVELOPMENTS!! PLEASE VOTE IN THIS POLL:


http://www.lxowners.com/forum/showthread.php?t=216

[MoPower]

Nice work. Does look like a ton of work. The finished product looks damn good!


Yes it is, that that is just the half of it, making the moulds is a whole another story!....oh, forgot, they you have to make the parts too

[MoPower]

After measuring very closely to confirm the dimensional accuracy, I found that the only problem is that the lower grille frame needed lowered 1/8" on the passenger side. That's not much but I want it perfect so I decided to just cut it and bond it back together to correct the problem. The 2nd pic shows it already bonded, then I just need to blend it in and re sculpt the corner.

http://i227.photobucket.com/albums/dd110/dankoreproductions/Rear%20Diffuser/bbb001.jpg
http://i227.photobucket.com/albums/dd110/dankoreproductions/Rear%20Diffuser/bbb002.jpg

IF YOU HAVEN'T VOTED YET, PLEASE CHOOSE YOUR FAVORITE PENDING DESIGN ON THIS THREAD:
http://www.lxowners.com/forum/showthread.php?t=216

[DaBlackPearl]

You have mad skills Mo...I wish I had some of them. Props to you sir.

[DanaM]

Mo glad you here at my new house. This is where I will get Danko updates from now on. Put me on the list please.

[MoPower]

First I want to thank everyone who voted, and say that as a direct results of the poll results, It has changed the course I was planning. First of all, let me explain: Option A and B are both old School and adding the rubber pads is very easy, so they are in the same category #1 since they will come from the same mould. Option C and D (open back and single tooth) can also come from the same moulds if I make a mould plug to fill in the single tooth before it's casted. What that basically means is that if I make the single tooth mould, I could also easily produce the open back from the same mould, hence they are also in the same category (category #2). Here are the final Poll results:

Category #1 (A&B): 2 - 33.3%
Category #2 (C&D): 4 - 66.6%

Because category # 2 is such a significant portion (66.6%), I just cannot ignore the market. That means I will have to make 2 moulds and basically product ALL of the 4 options (rubber pads may take a while...)
Now, to decide which one to start off with...well, that is a no brainer, the single tooth is easy to clean off for the next design, so I'm gonna start with that one, then once the mould is done, I'll convert it to the Old School Design and quickly make a mould of that one too! I'm Sure this decision will annoy some of you, and make very happy others but you know what they say...You can't please the all!

Today, I got A LOT done, basically the single tooth design is close to being done. I had to enlarge the whole a little more, but most importantly, I extended the bottom edge rearward another 1/2" in the center so the diffuser will be more visible and follow the lines better, so now lets hear what everyone has to say!


*
http://i227.photobucket.com/albums/dd110/dankoreproductions/Rear%20Diffuser/ttt0072.jpg
http://i227.photobucket.com/albums/dd110/dankoreproductions/Rear%20Diffuser/ttt0082.jpg
http://i227.photobucket.com/albums/dd110/dankoreproductions/Rear%20Diffuser/ttt0092.jpg
http://i227.photobucket.com/albums/dd110/dankoreproductions/Rear%20Diffuser/ttt0112.jpg
http://i227.photobucket.com/albums/dd110/dankoreproductions/Rear%20Diffuser/ttt0122.jpg

[MoPower]

New Progress!! I did tons of fine tweeking and then at the end of the day, laid down a heavy coat of filler primer. This should be in the mould stage next week.


http://i227.photobucket.com/albums/dd110/dankoreproductions/Rear%20Diffuser/jjj0012.jpg
http://i227.photobucket.com/albums/dd110/dankoreproductions/Rear%20Diffuser/jjj0032.jpg
http://i227.photobucket.com/albums/dd110/dankoreproductions/Rear%20Diffuser/jjj0042.jpg
http://i227.photobucket.com/albums/dd110/dankoreproductions/Rear%20Diffuser/jjj0062.jpg

[BOS/SRT]

Mo, badass!!!! btw, your killing me.... Lol

[MoPower]

IT's DONE!!!! Here is a Picture of the finished single tooth Diffuser. Mould should be in the works in just a couple of days!!

http://i227.photobucket.com/albums/dd110/dankoreproductions/Rear%20Diffuser/pppp0022.jpg

Here is a pic of me holding the pipes up in the correct position with my foot to get a peek!

http://i227.photobucket.com/albums/dd110/dankoreproductions/Rear%20Diffuser/pppp0062.jpg

My foot got tired, so I found a box to take my place...Many of you were concerned about whether your 4" tips would fit so I grabbed a piece of 4" alluminum pipe and stuck it on to give you an idea of how much space there is... I think 5" would fit in there too!!

http://i227.photobucket.com/albums/dd110/dankoreproductions/Rear%20Diffuser/pppp0102.jpg

[DanaM]

Im digging it. Cant wait to get my part. So will it be flat black when you ship?

[MoPower]

Im digging it. Cant wait to get my part. So will it be flat black when you ship? no, shiney black gelcoat like everything else.

[MoPower]

OK all you Charger fanatics! I'm just about ready to make the mould and this is a pretty easy one to do, so I'm thinking I better get the sales moving to help pay for the mould materials, etc...
Here is the plan: There are apparently at least 36 folks on the list who may want one of these Danko Charger Single Tooth diffusers. The $225 price is the planned GB (25% off) price with a retail price of $299. I can only handle doing 10 right now for that price, but I will put it up on our Danko website for anyone who wants one badly enough to pay the retail price. I'm doing this because they will probably be more costly to make then I had originally estimated and I don't want to get myself into a bad financial situation but I would like to get a few out there immediately so I can get some pics for my website.

What I am gonna do, is PM an order form to everyone on the list that PM's me and asks for it. Also, I'm posting the order form on here. The FIRST 10 that get the form filled out and sent back to me and paid in full (paypal only for the first 10 please) will get the Sale Price and a guaranteed spot as one of the first 10. You guys know how long it usually takes me to crank out the first ten of any new product, so please know that I will need as much time as it takes to get them done so if your car is in the body shop and you are in a big rush for it, it's probably not a good idea to get in on this deal. The Standard Hex Mesh will be included in each kit. In the future, we may (or may not) have a honeycomb upgrade for it, but if we did, that can be changed out later fairly easily. The diffuser will come in a black gel coat finish that will need painting. As all of our products, if you want us to prep and paint it Matte Black for you, just add $60 (make sure to note that when you send the form back). A rubber gasket and all hardware will be included along with instructions on how to mount it, and a perfect fit is gurananteed as usual. You will NOT have to cut out any portion of your rear bumper as is necessary with the Charger SRT diffuser. Shipping will be $35 Continental USA and $50 to Canada. Any more questions, please feel free to ask, and remember, when you see this message, there are probably already order forms being sent out, so HURRY IF YOU WANT TO BE ONE OF THE FIRST 10! BTW, if you didn't get an order form in your mailbox, PM me and I'll send you one ASAP!

[MoPower]

Diffuser List Candidates:
1) MZGUDZ--------->Form Sent
2) Dchavez--------->Form Sent
3) jay2puff--------->Form Sent
4) ecNick---------->Form Sent
5) CDNChargerRT--->Form Sent
6) 6Shooter-------->Form Sent
7) ChargerH2O----->Form Sent
8) Rock------------>Form Sent
9) blackhemi------->Form Sent
10) MAD HATTER--->Form Sent
11) carmodeler340-->Form Sent
12) Total Chaos----->Form Sent
13) SweetDaddy---->Form Sent
14) Daytona1117---->Form Sent
15) BReal02--------->Form Sent
16) silent76--------->Form Sent
17) bigvin7---------->Form Sent
18) FinallyCharged--->Form Sent
19) mx_mayhem----->Form Sent
20) gooeytek-------->Form Sent
21) dejuan71-------->Form Sent
22) wildwilers-------->Form Sent/failed
23) CrazyManInCincy->Form Sent
24) sergio------------>Form Sent
25) Sublimeon22s----->Form Sent
26) atwong1--------->Form Sent
27) aimeebb---------->Form Sent
28) Hemi------------->Form Sent
27) DanSS24--------->Form Sent
28) Diesel441-------->Form Sent
29) TexasFinest------>Form Sent
30) erniecon --------->Form Sent
31) SoSilver---------->Form Sent
32) 36 CHAMBERS----->Form Sent
33) Wellsy------------>Form Sent
34) Mymopar---------->Form Sent
35) Firewall----------->Form Sent
36) 06rthemi---------->Form Sent

[MoPower]

http://i227.photobucket.com/albums/dd110/dankoreproductions/Rear%20Diffuser/DSCN0345.jpg

[BOS/SRT]

Looking sweet Mo! Is done yet?

[MoPower]

The Charger Diffuser Mould will be done soon!! I'm now starting also on the Charger SRT8 front Spoiler (pictured below)

http://i227.photobucket.com/albums/dd110/dankoreproductions/Rear%20Diffuser/fffff003.jpg

http://i75.photobucket.com/albums/i317/moshefield/Charger/fffff004.jpg

[MoPower]

Got the first one done today and it fits perfectly and looks awesome on the car. I will be mounting it Monday and taking lots of install pics. The diffuser will mount with 9 small studs on the top edge and 3 nuts and bolts on the bottom and will have a foam rubber gasket.

[BOS/SRT]

Mo, sweet bro! Any pix yet? What about the SRT chin spoiler?

[MoPower]

Mo, sweet bro! Any pix yet? What about the SRT chin spoiler?

The spoiler mould should be done in a couple weeks. Here is the new Diffuser Installation thread !!

http://www.lxowners.com/forum/showthread.php?p=2613#post2613